US10889128B2 - Intermediate transfer member - Google Patents

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Publication number
US10889128B2
US10889128B2 US16/303,615 US201716303615A US10889128B2 US 10889128 B2 US10889128 B2 US 10889128B2 US 201716303615 A US201716303615 A US 201716303615A US 10889128 B2 US10889128 B2 US 10889128B2
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United States
Prior art keywords
itm
release layer
ink reception
reception surface
contact angle
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US16/303,615
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English (en)
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US20200062002A1 (en
Inventor
Benzion Landa
Sagi Abramovich
Moshe Levanon
Helena Chechik
Tatiana Kurtser
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Landa Corp Ltd
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Landa Corp Ltd
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Priority to US16/303,615 priority Critical patent/US10889128B2/en
Assigned to LANDA CORPORATION LTD. reassignment LANDA CORPORATION LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: ABRAMOVICH, SAGI, LANDA, BENZION, CHECHIK, HELENA, KURTSER, Tatiana, LEVANON, MOSHE
Publication of US20200062002A1 publication Critical patent/US20200062002A1/en
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    • B41M5/0353—Duplicating or marking methods; Sheet materials for use therein by transferring ink from the master sheet by sublimation or volatilisation of pre-printed design, e.g. sublistatic using heat shrinkable film material; Thermotransfer combined with the shaping of the workpiece; Recto-verso printing; Image correction
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/744—Non-slip, anti-slip
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/748—Releasability
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/75—Printability
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2310/00—Treatment by energy or chemical effects
    • B32B2310/08—Treatment by energy or chemical effects by wave energy or particle radiation
    • B32B2310/0806—Treatment by energy or chemical effects by wave energy or particle radiation using electromagnetic radiation
    • B32B2310/0825—Treatment by energy or chemical effects by wave energy or particle radiation using electromagnetic radiation using IR radiation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2311/00—Metals, their alloys or their compounds
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2311/00—Metals, their alloys or their compounds
    • B32B2311/24—Aluminium
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2317/00—Animal or vegetable based
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2367/00—Polyesters, e.g. PET, i.e. polyethylene terephthalate
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2559/00—Photographic equipment or accessories
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/40—Layered products comprising a layer of synthetic resin comprising polyurethanes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/24—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer not being coherent before laminating, e.g. made up from granular material sprinkled onto a substrate

Definitions

  • the invention relates to the field of printing and, more particularly, to intermediate transfer members of printing systems.
  • the ITM is typically a sleeve mounted on a drum or a looped blanket forming a flexible belt on a conveyor system.
  • Blankets suitable as intermediate transfer members require certain structural characteristics to make them suitable for the type of ink transfer envisioned and for the printing systems in which they are intended to operate.
  • the desired properties of the blanket are generally achieved by using multi-layered structures in which the release layer may be a silicone-based polymer having suitable ink attachment and release properties, and in which the blanket base includes at least one layer adapted to support the release layer.
  • a printing cycle known in the art of indirect printing, may include the following steps:
  • the inks may be applied to the image transfer surface by ink-jetting, typically at a printing station.
  • the residue film obtained may be transferred from the image transfer surface to the substrate at an impression station, by engaging the intermediate transfer member with an impression cylinder.
  • ITM release layers having characteristically low surface energies are advantageous in that they may facilitate transfer of the dried ink image to the printing substrate.
  • the aqueous ink drops jetted onto such a low-energy, hydrophobic release layer tend to bead after the initial impact, thereby compromising image quality.
  • Higher-energy, less hydrophobic release layers may mitigate this effect, but are detrimental to image transfer quality.
  • the process must contend with various issues pertaining to untransferred ink remaining on the release layer surface. In high-speed, high-throughput digital printing systems, these problems become even more acute.
  • the ITM may be required to have several specific physical properties that may be achieved by having a complex multi-layer structure.
  • the ITM includes a support layer, typically including a fabric, the support layer having a very limited elasticity to avoid deformation of an image during transport to an impression station.
  • the ITM may additionally have a highly compliant thin layer immediately beneath the release later to enable the tacky film to closely follow the surface contour of the substrate.
  • the ITM may include other layers to achieve the various desired frictional, thermal, and electrical properties of the ITM.
  • the support layer is used as the starting point when making an ITM. Specifically, manufacture of an ITM is performed by providing a support layer to which additional desired layers are added to construct the desired multi-layer structure. Typically, the different layers of the ITM are applied as a curable fluid.
  • the release layer having the ink transfer surface of the ITM is the last and uppermost layer that is applied and formed.
  • the inventors have observed that the topography, contour and even surface finish of the ink transfer surface may be determined to a large extent by the contour of the surface of the penultimate layer to which the incipient release layer is applied. For this reason, it has proven difficult to manufacture an ITM having a defect-free ink transfer surface with a desired surface finish. The inventors have found that such defects may appreciably detract, in various ways, from release layer performance, a problem particularly aggravated when significant length, width and surfaces of ITM are desired.
  • the inventors have recognized the need for improved release layers that are better adapted to deal with the contradictory tasks pertaining to the aqueous ink reception stage, requiring hydrophilic properties, and the ink-film transfer stage, requiring hydrophobic properties.
  • an intermediate transfer member (ITM) for use with a printing system including:
  • the ITM satisfies at least one, and as many as all, of the following structural properties:
  • a total surface energy of the ink reception surface is at least 2 J/m2, at least 3 J/m2, at least 4 J/m2, at least 5 J/m2, at least 6 J/m2, at least 8 J/m2, or at least 10 J/m2 higher than a total surface energy of a modified ink reception surface produced by subjecting an ink reception surface of a corresponding release layer to a standard aging procedure;
  • a total surface energy of the ink reception surface is at least 4 J/m2, at least 6 J/m2, at least 8 J/m2, at least 10 J/m2, at least 12 J/m2, at least 14 J/m2, or at least 16 J/m2 than a total surface energy of a hydrophobic ink reception surface of a corresponding release layer prepared by standard air curing of a silicone precursor of the cured silicone material;
  • a receding contact angle of a droplet of distilled water on the ink reception surface is at least 7°, at least 8°, at least 10°, at least 12°, at least 14
  • the addition-cured silicone material consisting essentially of an addition-cured silicone, or containing, by weight, at least 95%, at least 96%, at least 97%, at least 98%, or at least 99% of the addition-cured silicone.
  • functional groups make up at most 5%, at most 3%, at most 2%, or at most 1%, by weight, of the addition-cured silicone material, or the addition-cured silicone material is substantially devoid of the functional groups.
  • a polyether glycol functionalized polydimethyl siloxane is impregnated in the addition-cured silicone material.
  • a polyether glycol functionalized siloxane is impregnated in the addition-cured silicone material, but without forming a part of a covalent structure of the addition-cured silicone material.
  • the thickness of the release layer is at most 500 ⁇ m, at most 200 ⁇ m, at most 100 ⁇ m, at most 50 ⁇ m, at most 25 ⁇ m, or at most 15 ⁇ , and optionally, within a range of 4 to 400 ⁇ m, 5 to 250 ⁇ m, 5 to 100 ⁇ m, 5 to 60 ⁇ m, 8-100 ⁇ m, 10-100 ⁇ m, or 10-80 ⁇ m.
  • the thickness of the support layer is within a range of about 50-2700 ⁇ m, 50-1500 ⁇ m, 50-1000 ⁇ m, 100-1000 ⁇ m, 100-800 ⁇ m, or 100-500 ⁇ m.
  • the ITM satisfies structural property (1).
  • the ITM satisfies structural property (2).
  • the ITM satisfies structural property (3).
  • the ITM satisfies structural property (4).
  • the ITM satisfies structural property (5).
  • the ITM satisfies structural property (6).
  • the ITM satisfies structural property (7).
  • the ITM satisfies structural property (8).
  • the ITM satisfies structural property (9).
  • the ITM satisfies structural property (10).
  • the ITM satisfies structural property (11).
  • the ITM forms a component in a digital printing system.
  • the support layer includes an elastomeric compliance layer attached to the second surface of the release layer, the elastomeric compliance layer adapted to follow closely a surface contour of a printing substrate onto which the ink image is impressed.
  • the support layer includes a reinforcement layer attached to the compliance layer.
  • the release layer contains, within a silicone polymer matrix thereof, a total amount of at most 3%, at most 2%, at most 1%, at most 0.5%, at most 0.2%, or substantially 0% of the functional groups, by weight.
  • the release layer contains, within a silicone polymer matrix thereof, a total amount of at most 3%, at most 2%, at most 1%, at most 0.5%, at most 0.2%, or substantially 0%, by weight, of functional groups selected from the group of moieties consisting of C ⁇ O, S ⁇ O, O—H, and COO.
  • the release layer contains, within a silicone polymer matrix thereof, a total amount of at most 3%, at most 2%, at most 1%, at most 0.5%, at most 0.2%, or substantially 0%, by weight, of functional groups selected from the group consisting of silane, alkoxy, amido, and amido-alkoxy moieties.
  • the release layer contains, within a silicone polymer matrix thereof, a total amount of at most 3%, at most 2%, at most 1%, at most 0.5%, at most 0.2%, or substantially 0%, by weight, of functional groups selected from the group consisting of amine, ammonium, aldehyde, SO 2 , SO 3 , SO 4 , PO 3 , PO 4 , and C—O—C moieties.
  • the addition-cured silicone material has a structure built from a vinyl-functional silicone.
  • the addition-cured silicone material includes polar groups of the “MQ” type.
  • the total surface energy of the ink reception surface is evaluated using the Owens-Wendt Surface Energy Model.
  • the polar groups include O—Si—O groups.
  • the orientation away from the second surface, or towards the ambient environment is at least 55%, at least 60%, at least 65%, at least 70%, at least 75%, or at least 80% of the polar groups, on a molar or weight basis.
  • the ITM has a length of up to 20 meters, and typically, within a range of 5-20, 5-15, 5-12, or 7-12 meters.
  • the ITM has a width of up to 2.0 meters, and typically, within a range of 0.3-2.0, 0.75-2.0, 0.75-1.5, or 0.75-1.25 meters.
  • the ITM has a thickness of up to 3000 ⁇ m, and typically, within a range of 200-3000, 200-1500, 300-1000, 300-800, 300-700, 100-3000, 50-3000, or 100-600 ⁇ m.
  • intermediate transfer member refers to the component of a printing system upon which the ink is initially applied by the printing heads, for instance by inkjet heads, and from which the jetted image is subsequently transferred to another substrate or substrates, typically, the final printing substrates.
  • blanket refers to a flexible transfer member that can be mounted within a printing device on a drum, or can be a belt-like structure supported by two or more rollers, at least one of which able to rotate and move the belt to travel around the rollers.
  • FIG. 1 schematically shows a section through a carrier
  • FIGS. 2 to 6 schematically exhibit different stages in the manufacture of an ITM, according to the present method
  • FIG. 7 is a section through a finished ITM after installation in a printing system
  • FIGS. 8A and 8B schematically illustrate a cross section through a release layer prepared according to the prior art
  • FIG. 8C schematically illustrates a cross section through a release layer prepared according to the present method
  • FIGS. 9A to 9D schematically display an apparatus in which some embodiments of the present method can be implemented, different manufacturing stages being illustrated;
  • FIGS. 10A-10C are images of various ink patterns printed onto a release layer of an ITM of the present invention, in which the release layer was cured against a PET carrier surface;
  • FIGS. 11A-11C are images of various ink patterns printed onto a release layer of an ITM of the prior art, in which the release layer was air cured.
  • the ITM may be manufactured in the inventive manner described by FIGS. 2-7 and in the description associated therewith. Such an ITM may be particularly suitable for the Nanographic PrintingTM technologies of Landa Corporation.
  • FIG. 1 schematically shows a section through a carrier 10 .
  • the carrier 10 is shown as a solid black line.
  • Carrier 10 has a carrier contact surface 12 .
  • carrier contact surface 12 may be a well-polished flat surface having a roughness (Ra) of at most about 50 nm, at most 30 nm, at most 20 m, at most 15 nm, at most 12 nm, or more typically, at most 10 nm, at most 7 nm, or at most 5 nm. In some embodiments, carrier contact surface 12 may between 1 and 50 nm, between 3 and 25 nm, between 3 and 20 nm, or between 5 nm and 20 nm.
  • the hydrophilic properties of the carrier contact surface 12 are described hereinbelow.
  • carrier 10 may be inflexible, being formed, for example, of a sheet of glass or thick sheet of metal.
  • carrier 10 may advantageously be formed of a flexible foil, such as a flexible foil mainly consisting of, or including, aluminum, nickel, and/or chromium.
  • the foil is a sheet of aluminized PET (polyethylene terephthalate, a polyester), e.g., PET coated with fumed aluminum metal.
  • the top coating of aluminum may be protected by a polymeric coating, the sheet typically having a thickness of between 0.05 mm and 1.00 mm so as to remain flexible but difficult to bend through a small radius, so as to avert wrinkling.
  • carrier 10 may advantageously be formed of an antistatic polymeric film, for example, a polyester film such as PET.
  • the anti-static properties of the antistatic film may be achieved by various means known to those of skill in the art, including the addition of various additives (such as an ammonium salt) to the polymeric composition.
  • a fluid first curable composition (illustrated as 36 in FIG. 9B ) is provided and a layer 16 is formed therefrom on carrier contact surface 12 , layer 16 constituting an incipient release layer having an outer ink-transfer surface 14 .
  • the fluid first curable composition of layer 16 may include an elastomer, typically made of a silicone polymer, for example, a polydimethylsiloxane, such as a vinyl-terminated polydimethylsiloxane.
  • an elastomer typically made of a silicone polymer, for example, a polydimethylsiloxane, such as a vinyl-terminated polydimethylsiloxane.
  • the fluid first curable material includes a vinyl-functional silicone polymer, e.g., a vinyl-silicone polymer including at least one lateral vinyl group in addition to the terminal vinyl groups, for example, a vinyl-functional polydimethyl siloxane.
  • a vinyl-functional silicone polymer e.g., a vinyl-silicone polymer including at least one lateral vinyl group in addition to the terminal vinyl groups, for example, a vinyl-functional polydimethyl siloxane.
  • the fluid first curable material includes a vinyl-terminated polydimethylsiloxane, a vinyl-functional polydimethylsiloxane including at least one lateral vinyl group on the polysiloxane chain in addition to the terminal vinyl groups, a crosslinker, and an addition-cure catalyst, and optionally further includes a cure retardant.
  • the curable adhesive composition may include any suitable amount of addition cure catalyst, typically at most 0.01% of the pre-polymer, on a per mole basis.
  • Layer 16 of the fluid first curable composition is applied to carrier contact surface 12 , and is subsequently cured.
  • Layer 16 may be spread to the desired thickness using, for example, a doctor blade (a knife on a roll), without allowing the doctor blade to contact the surface that will ultimately act as the ink-transfer surface 14 of the ITM, such that imperfections in the doctor blade will not affect the quality of the finished product.
  • “release” layer 16 may have a thickness of between about 2 micrometers and about 200 micrometers. An apparatus in which such step and method can be implemented is schematically illustrated in FIGS. 9A and 9B .
  • the above-detailed release layer formulation may be uniformly applied upon a PET carrier, leveled to a thickness of 5-200 micrometers ( ⁇ ), and cured for approximately 2-10 minutes at 120-130° C.
  • the hydrophobicity of the ink transfer surface of the release layer so prepared as assessed by its receding contact angle (RCA) with a 0.5-5 microliter ( ⁇ l) droplet of distilled water, may be around 60°, whereas the other side of the same release layer (which served to approximate the hydrophobicity of a layer conventionally prepared with an air interface) may have an RCA that is significantly higher, typically around 90°.
  • PET carriers used to produce ink-transfer surface 14 may typically display an RCA of around 40° or less. All contact angle measurements were performed with a Contact Angle analyzer—KrüssTM “Easy Drop” FM40 Mk2 and/or a Dataphysics OCA15 Pro (Particle and Surface Sciences Pty. Ltd., Gosford, NSW, Australia).
  • an additional layer 18 is applied to layer 16 , on the side opposite to ink-transfer surface 14 .
  • Compliance layer 18 is an elastomeric layer that allows layer 16 and its outermost surface 14 to follow closely the surface contour of a substrate onto which an ink image is impressed.
  • the attachment of compliance layer 18 to the side opposite to ink-transfer surface 14 may involve the application of an adhesive or bonding composition in addition to the material of compliance layer 18 .
  • compliance layer 18 may typically have a thickness of between about 100 micrometers and about 300 micrometers or more.
  • compliance layer 18 may have the same composition as that of release layer 16 , material and process economics may warrant the use of less expensive materials. Moreover, compliance layer 18 typically is selected to have mechanical properties (e.g., greater resistance to tension) that differ from release layer 16 . Such desired differences in properties may be achieved, by way of example, by utilizing a different composition with respect to release layer 16 , by varying the proportions between the ingredients used to prepare the formulation of release layer 16 , and/or by the addition of further ingredients to such formulation, and/or by the selection of different curing conditions. For instance, the addition of filler particles may favorably increase the mechanical strength of compliance layer 18 relative to release layer 16 .
  • compliance layer 18 may include various rubbers. Preferably such rubbers are stable at temperatures of at least 100° C., and may include rubbers such as alkyl acrylate copolymer rubbers (ACM), methyl vinyl silicone rubber (VMQ), ethylene propylene diene monomer rubber (EPDM), fluoroelastomer polymers, nitrile butadiene rubber (NBR), ethylene acrylic elastomer (EAM), and hydrogenated nitrile butadiene rubber (HNBR).
  • ACM alkyl acrylate copolymer rubbers
  • VMQ methyl vinyl silicone rubber
  • EPDM ethylene propylene diene monomer rubber
  • fluoroelastomer polymers fluoroelastomer polymers
  • NBR nitrile butadiene rubber
  • EAM ethylene acrylic elastomer
  • HNBR hydrogenated nitrile butadiene rubber
  • Silopren® LSR 2530 Momentive Performance Materials Inc., Waterford N.Y.
  • a two-component liquid silicone rubber in which the two components are mixed at a 1:1 ratio, was applied to the cured release layer 16 previously described.
  • the silicone rubber mixture was metered/leveled with a knife blade to obtain an incipient compliance layer 18 having a thickness of about 250 micrometers, which was then cured for approximately 5 minutes at 150-160° C.
  • a reinforcement layer or support layer 20 is constructed on compliance layer 18 .
  • Support layer 20 typically contains a fiber reinforcement, in the form of a web or a fabric, to provide support layer 20 with sufficient structural integrity to withstand stretching when the ITM is held in tension in the printing system.
  • Support layer 20 is formed by coating the fiber reinforcement with a resin that is subsequently cured and remains flexible after curing.
  • support layer 20 may be separately formed as a reinforcement layer, including such fibers embedded and/or impregnated within the independently cured resin.
  • support layer 20 may be attached to compliance layer 18 via an adhesive layer, optionally eliminating the need to cure the support layer 20 in situ.
  • support layer 20 whether formed in situ on compliance layer 18 or separately, may have a thickness of between about 100 micrometers and about 500 micrometers, part of which is attributed to the thickness of the fibers or the fabric, which thickness generally varies between about 50 micrometers and about 300 micrometers.
  • the support layer thickness is not limiting.
  • the support layer may have a thickness of more than 200 micrometers, more than 500 micrometers, or 1 mm or more.
  • a support layer 20 including woven fabric of glass fibers including woven fabric of glass fibers.
  • the glass fiber fabric having a thickness of about 100 micrometers, was a plain weave fabric having 16 yarns/cm in perpendicular directions.
  • the glass fiber fabric was embedded into a curable fluid including a liquid silicone rubber Silopren® LSR 2530 corresponding to the compliance layer.
  • the resulting support layer 20 had a thickness of about 200 micrometers and was cured at 150° C. for approximately 2-5 minutes.
  • more dense weave fabrics e.g., having 24 ⁇ 23 yarns/cm may be used.
  • FIG. 5 shows an optional felt blanket 22 secured (e.g., by a cured adhesive or resin) to the reverse side of support layer 20
  • FIG. 6 shows a high friction layer 24 coated onto the reverse side of blanket 22 .
  • various relatively soft rubbers may serve for the preparation of a layer having high friction properties, silicone elastomers being but an example of such rubbers.
  • high friction layer 24 may be attached directly to support layer 20 .
  • all layers e.g., 18 , 20 , 22 , 24 , or any intervening adhesive or priming layer and the like
  • added to the release layer of the ITM are the to jointly form the base of the structure, as shown with respect to base 200 in FIG. 8C .
  • the finished product can simply be peeled away from carrier 10 .
  • the carrier 10 is a flexible foil, it may be preferred to leave it in place on the ITM until such time as the ITM is to be installed into a printing system.
  • the foil will act to protect the ink-transfer surface 14 of the ITM during storage, transportation and installation. Additionally, carrier 10 can be replaced, following completion of the manufacturing process, by an alternative foil that is suitable as a protective film.
  • FIGS. 9A to 9D schematically illustrate an apparatus 90 in which the ITM may be manufactured.
  • FIG. 9A provides a schematic overview of such an apparatus 90 having an unwinding roller 40 and a winding roller 42 moving a flexible loop conveyor 100 .
  • a dispensing station 52 able to dispense curable fluid compositions suitable for the desired ITMs
  • a leveling station 54 able to control the thickness of the curable layer as it moves downstream of the station
  • a curing station 56 able to at least partially cure the layer enabling it to serve as incipient layer for a subsequent step, if any.
  • the dispensing station 52 , the leveling station 54 and the curing station 56 constitute a layer forming station 50 a .
  • apparatus 90 may optionally include more than one layer forming station.
  • a forming station 50 may include additional sub-stations, illustrated by a dispensing roller 58 in station 50 a.
  • carrier 10 is directly tensioned between rollers 40 and 42 .
  • Unprocessed carrier 10 is unwound from unwinding roller 40 , and after passing through stations 50 a and 50 b , is rewound onto winding roller 42 .
  • the apparatus may further include upstream of the dispensing station a “surface treatment” station facilitating the subsequent application of a curable composition, or its attachment to the carrier contact surface or incipient layer as the case may be.
  • a “surface treatment” station facilitating the subsequent application of a curable composition, or its attachment to the carrier contact surface or incipient layer as the case may be.
  • the optional surface treatment station can be suitable for physical treatment (e.g., corona treatment, plasma treatment, ozonation, etc.).
  • FIG. 9B schematically illustrates how in a forming station 50 of apparatus 90 , a carrier 10 placed on conveyor 100 can be coated.
  • the curable composition 36 of release layer 16 is applied to carrier contact surface 12 .
  • the curable composition 36 is leveled to a desired thickness at leveling station 54 , for instance, by using a doctor blade.
  • the leveled layer proceeds downstream, it enters curing station 56 , configured so as to at least partially cure curable composition 36 , enabling the formation of incipient layer 16 at the exit side of the curing station.
  • curing station 56 configured so as to at least partially cure curable composition 36 , enabling the formation of incipient layer 16 at the exit side of the curing station.
  • FIGS. 9C and 9D schematically illustrate how additional layers (forming the base) can be applied.
  • a curable composition 38 is dispensed at dispensing station 52 (which can be same or different than the station having served to coat the carrier with the release layer 16 , as illustrated in FIG. 9B ).
  • Curable composition 38 is leveled to a desired thickness at leveling station 54 , then enters curing station 56 , and exits curing station 56 sufficiently cured to serve as incipient layer 18 for a subsequent step, and so on.
  • FIG. 9C schematically depicts a curable composition 39 being applied at dispensing station 52 .
  • a support layer e.g., a fabric
  • the backbone of a support layer can be delivered by dispensing roller 58 .
  • the exemplary fabric can be submerged into the curable composition at a station 60 prior to their entry into curing station 56 .
  • a support layer 20 can be formed at the exit side of the curing station.
  • FIGS. 8A and 8B schematically illustrate how defects would appear in a section of an outer layer 80 (e.g., a release layer) prepared according to the above-described method of the art.
  • FIG. 8A illustrates different phenomena relating to air bubbles, which may be entrapped in any curable composition if the curing occurs before such bubbles can be eliminated (e.g., by degassing).
  • tiny bubbles 82 migrate towards the air interface, the orientation of layer 80 during manufacturing over a body 800 , hence the direction of migration, being indicated by an arrow, they can merge into larger bubbles.
  • the bubbles may either remain entrapped within the bulk of the layer or on its surface, the upper part of the bubbles envelope forming protrusions 84 .
  • craters 86 may remain, even if the segment of the envelope of the bubbles protruding from the surface has disappeared.
  • FIG. 8B schematically illustrates different phenomena relating to solid contaminants, such as dust.
  • the dust is represented as being in addition to air bubbles, this need not be necessarily the case, each such surface or layer defect able to occur independently.
  • solid contaminants may remain upon the surface. If the settling of contaminants occurs after the outer layer 80 is cured, then such contaminants 92 may even be removed by suitable cleaning of the outer surface. Still, such a phenomenon is undesirable, as it would require additional processing of such an ITM before being able to use it.
  • the contaminants can be either entrapped on the surface of layer 80 , (e.g., contaminant 94 , which appears to be “floating”), or can even be submerged within the release layer, (e.g., contaminant 96 ). As can be readily understood, larger/heavier contaminants may sink more deeply than smaller ones.
  • the method disclosed herein includes forming a layer of a fluid first curable material with one side of the layer contacting a carrier contact surface, the layer constituting an incipient release layer.
  • the carrier contact surface functions to protect the incipient release layer, giving the ink transfer layer desired properties, while the carrier acts as a physically robust support structure onto which other layers are added to form the ITM, until the ITM is complete.
  • the finish of the ink transfer surface is primarily, if not exclusively, determined by the carrier contact surface.
  • FIG. 8C schematically illustrates a section through an outer layer 16 (e.g., a release layer) prepared according to the present method.
  • the section is shown without a carrier and in the same orientation as FIGS. 8A and 8B , though the manufacturing is performed in inversed orientation as shown by the arrow.
  • the base 200 which, as shall be detailed hereinafter, is attached to the first outer layer 16 after the layer is at least partially cured, is therefore not equivalent to body 800 already serving as support during the manufacturing process.
  • layer 16 is represented as including an important number of bubbles 82 , but this need not be the case. However, if present, such bubbles would display a distinct pattern than those previously described.
  • the release layer being therefore devoid of phenomena such as previously illustrated by surface protruding bubbles 84 .
  • craters previously illustrated as cavities 86 are very unlikely, as they would imply using an incompatible curable layer and carrier.
  • the curable material due to form the outer layer is to suitably wet the carrier, it is believed that substantially no air bubbles can be entrapped between the carrier and the incipient layer formed thereon. Thus, if at all present, such bubbles would be disposed in the bulk of the layer.
  • inventive release layer structures of the present invention may contain substantially no functional groups, or an insubstantial amount (e.g., an insubstantial amount of OH groups), covalently attached within the polymer matrix.
  • Such functional groups may include moieties such as C ⁇ O, S ⁇ O, and OH, by way of example.
  • release layer structures contain, at most, an insubstantial amount of such functional groups, it would be expected that the release layers thereof would be highly hydrophobic.
  • the inventors have surprisingly found, however, that the release layer surfaces produced by the present method may actually be somewhat hydrophilic, and appreciably more hydrophilic than corresponding release layers, i.e., release layers having the same composition, but manufactured using the conventional curing technique in which the release layer is exposed to air (“standard air curing”). Without wishing to be bound by theory, the inventors believe that the intimate contact between the carrier contact surface and the incipient release layer surface, the somewhat hydrophilic properties of the carrier contact surface are induced in the release layer surface.
  • ITM release layers having low surface energies may facilitate transfer of the dried ink image to the printing substrate.
  • the aqueous ink drops jetted onto such a low-energy, hydrophobic release layer tend to bead after the initial impact, thereby compromising image quality.
  • Higher-energy, less hydrophobic release layers may mitigate this effect, but are detrimental to image transfer quality.
  • the release layer structures of the present invention typically have release surfaces of characteristically moderated hydrophobicity, as manifested by receding contact angles for distilled water of at most 80°, or at most 70°, typically, at most 60°, or at most 50°, and more typically, 30°-60°, 35°-60°, 30°-55°, 30°-50°, 30°-45°, or 35°-50°.
  • both the ink reception and the transfer of the dry, heated ink image may be of good quality.
  • the inventors believe that the above-described induced surface properties improve the interactions between polar groups (e.g., O—Si—O) on the release layer surface and corresponding polar moieties (e.g., OH groups in the water) in the aqueous liquids (e.g., aqueous inkjet inks) deposited thereon, thereby contributing to the reception of the jetted ink drops. Subsequently, after drying the ink and heating of the ink film to transfer temperatures, these interactions are weakened, enabling complete transfer of the dry or substantially dry ink image.
  • polar groups e.g., O—Si—O
  • corresponding polar moieties e.g., OH groups in the water
  • the carriers used as substrates in the production of the release layer surface include (1) an anti-static polyester film (Examples 1-7); (2) an untreated polyester film i.e., not anti-static (Example 11); and (3) an aluminized polyester film (Example 10).
  • the ITM release layer of Example 1 had the following composition (wt./wt.):
  • the desired thickness of the incipient release layer was coated on a PET sheet, using a rod/knife (other coating methods may also be used), followed by curing for 3 minutes at 150° C.
  • Siloprene LSR 2530 was coated on top of the release layer, using a knife, to achieve a desired thickness. Curing was then performed at 150° C. for 3 minutes.
  • An additional layer of Siloprene LSR 2530 was then coated on top of the previous (cured) silicone layer, and fiberglass fabric was incorporated into this wet, fresh layer such that wet silicone penetrated into the fabric structure. Curing was then performed at 150° C. for 3 minutes.
  • a final layer of Siloprene LSR 2530 was then coated onto the fiberglass fabric and, once again, curing was performed at 150° C. for 3 minutes. The integral blanket structure was then cooled to room temperature and the PET was removed.
  • the ITM release layer of Example 2 has the following composition:
  • the ITM release layer of Example 3 has the following composition:
  • the ITM release layer of Example 4 has the following composition:
  • the ITM release layer of Example 5 was prepared from Silopren® LSR 2530 (Momentive Performance Materials Inc., Waterford, N.Y.), a two-component liquid silicone rubber, in which the two components are mixed at a 1:1 ratio.
  • the blanket was prepared substantially as described in Example 1.
  • the ITM release layer of Example 6 has a composition that is substantially identical to that of Example 4, but includes SR545 (Momentive Performance Materials Inc., Waterford, N.Y.), a commercially available silicone-based resin containing polar groups.
  • the polar groups are of the “MQ” type, where “M” represents Me 3 SiO and “Q” represents SiO 4 .
  • the full composition is provided below:
  • the ITM release layer of Example 7 has a composition that is substantially identical to that of Example 6, but includes polymer RV 5000, which includes vinyl-functional polydimethyl siloxanes having a high density of vinyl groups, as described hereinabove.
  • the full composition is provided below:
  • ITM release layers were prepared as “corresponding release layers” or “reference release layers” to the compositions of Examples 1-6, such that the corresponding release layers (designated Comparative Examples 1A-1F) had the identical compositions as Examples 1-6, respectively.
  • the release layer surface or “ink reception surface” was exposed to air (“standard air curing”), according to a conventional preparation procedure, provided below.
  • a first layer of Siloprene LSR 2530 was coated on a PET sheet, using a rod/knife, followed by curing for 3 min at 150° C., to achieve the desired thickness.
  • An additional layer of Siloprene LSR 2530 was then coated on top of the previous (cured) silicone layer, and fiberglass fabric was incorporated into this wet, fresh layer such that wet silicone penetrated into the fabric structure.
  • Siloprene LSR 2530 was then coated on top of the fiberglass fabric, and curing ensued at 150° C. for 3 minutes. Prior to forming the incipient release layer, all components of the release layer formulation were thoroughly mixed together.
  • the release layer was coated on top of cured Siloprene LSR 2530 to achieve the desired thickness, and was subsequently cured at 150° C. for 3 minutes, while the release layer surface was exposed to air.
  • the release surfaces produced against the carrier surfaces exhibited lower Receding Contact Angles than the identical formulation, cured in air. More typically, the release surfaces produced against the carrier surfaces exhibited Receding Contact Angles that were lower by at least 5°, at least 7°, at least 10°, at least 12°, or at least 15°, or were lower within a range of 5°-30°, 7°-30°, 10°-30°, 5°-25°, 5°-22°, 7°-25°, or 10°-25°.
  • Example 1 75° 80° Comparative 95° 95° Example 1A
  • Example 2 45° 60° Comparative 65° 65° Example 1B
  • Example 3 40° 50° Comparative 63° 65° Example 1C
  • Example 4 65° 62° Comparative 79° 75° Example 1D
  • Example 5 70° 74° Comparative 80° 80°
  • Example 1E Example 6 56° 70° Comparative 74° 70° Example 1F
  • the receding contact angle is substantially maintained after performing the aging process.
  • inventive Examples 1-6 it is evident that the receding contact angle increases, typically by 4°-15°, after performing the aging process.
  • the increase in contact angle in the inventive release layer structures may be attributed to a loss in hydrophilic behavior (or increased hydrophobic behavior) due to some change in the position of the polar groups (e.g., Si—O—Si) at the release layer surface.
  • a blanket including a release layer of the composition of Example 2 was prepared substantially as described in Example 1, but against an aluminized PET carrier surface.
  • a release layer having the release layer composition of Example 2 was prepared substantially as described in Example 1, but against a commercially available PET carrier surface that was not subjected to an anti-static pre-treatment.
  • Release formulation Carrier film RCA vs. Carrier Example 10 Aluminized PET 62° Example 11 PET without anti- 62° static treatment
  • Example 2 PET with anti- 45° static treatment
  • Examples 10 and 11 exhibited receding contact angles that were about 30° less than the receding contact angle of the same composition cured with the release layer exposed to air.
  • the release layer surface of Example 2 prepared against an anti-static PET carrier surface, displayed a receding contact angles that was about 50° less than the receding contact angle of the same composition prepared while exposed to air.
  • the hydrophilic behavior of the carrier surfaces has been at least partially induced in the respective release surfaces: the formulation cured while exposed to air has an RCA of 65°; the same formulation, prepared against an antistatic PET surface, has an RCA of 45°; the anti-static PET carrier used displays an RCA of 20°.
  • the inventive release layer structure has a release surface whose hydrophilicity/hydrophobicity properties lie in between the properties of the same formulation, cured in air, and the carrier surface itself.
  • Release layer surface energies were calculated for ink reception surfaces of the following Examples: Example 1A, cured under exposure to air; Example 1, cured against an anti-static PET surface; and Example 1, cured against an anti-static PET surface and then subjected to the standard aging procedure at 160° C., for 2 hours.
  • the three Examples have the identical chemical formulation.
  • the total surface energy was calculated using the classic “harmonic mean” method (also known as the Owens-Wendt Surface Energy Model, see, by way of example, KRUSS Technical Note TN306e). The results are provided below:
  • Example 1A cured under exposure to air, the release layer surface is extremely hydrophobic, and the total surface energy of the surface is low, 20.9 J/m 2 , as expected. This is fairly close to the literature value for surface energy, for polydimethylsiloxane (PDMS).
  • PDMS polydimethylsiloxane
  • Example 1 which was cured against an anti-static PET surface, exhibited a total surface energy of about 26 J/m 2 , which is moderately less hydrophobic than the “air-cured” sample. After this formulation was subjected to the standard aging procedure, the total surface energy decreased from about 26 J/m 2 to under 26 J/m 2 . This result would appear to corroborate the RCA results obtained for the various aged and un-aged materials of this exemplary formulation.
  • Release layer surface energies were calculated for ink reception surfaces of the following Examples: Example 2A, cured under exposure to air; Example 2, cured against an anti-static PET surface; and Example 2, cured against an anti-static PET surface and then subjected to the standard aging procedure at 160° C., for 2 hours.
  • the three Examples have the identical chemical formulation.
  • Example 2A Air Cured 34.6
  • Example 2A cured under exposure to air, the release layer surface is less hydrophobic than the release layer of Example 1A, the total surface energy of the surface being about 35 J/m2.
  • Example 2 cured against an anti-static PET surface, exhibited a total surface energy of about 49 J/m2, which is significantly less hydrophobic than the “air-cured” sample. After this formulation was subjected to the standard aging procedure, the total surface energy decreased from about 49 J/m2 to about 40 J/m2. This result would appear to corroborate the RCA results obtained for the various aged and un-aged materials of this exemplary formulation.
  • the temperature on the blanket surface is maintained at 75° C.
  • the image (typically a color gradient of 10-100%) is printed at a speed of 1.7 m/sec on the blanket, at a resolution of 1200 dpi.
  • An uncoated paper (A4 Xerox Premium Copier Paper, 80 gsm) is set between the pressure roller and the blanket and the roller is pressed onto blanket, while the pressure is set to 3 bar. The roller moves on the paper, applying pressure on the contact line between blanket and paper and promoting the transfer process. In some cases, incomplete transfer may be observed, with an ink residue remaining on the blanket surface.
  • glossy paper (A4 Burgo glossy paper 130 gsm) is applied on the blanket similarly to the uncoated paper and the transfer process is again performed. Any ink that remained on blanket and was not transferred to the uncoated paper will be transferred to the glossy paper.
  • the glossy paper may be evaluated for ink residue, according to the following scale (% of image surface area):
  • Example 16 was repeated for the release surfaces of Examples 2 and 3, but at a printing speed of 3.4 m/sec on the blanket. Both release surfaces retained a transfer grade of A.
  • the ITM release layer compositions of Examples 2 and 3 were cured against a PET substrate according to the procedure provided in Example 1.
  • the ITM release layer compositions of Examples 2 and 3 were cured against air, according to the procedure provided in Comparative Examples 1B and 1C.
  • the samples were then subjected to dynamic contact angle (DCA) measurements at 10 seconds and subsequently at 70 seconds, according to the following procedure:
  • the drop is placed onto a smooth PTFE film surface with as little drop falling as possible, so that kinetic energy does not spread the drop.
  • a pendant drop is then formed.
  • the specimen is raised until it touches the bottom of the drop. If the drop is large enough, the adhesion to the surface will pull it off the tip of the needle.
  • the needle tip is positioned above the surface at such a height that the growing pendant drop will touch the surface and detach before it falls free due to its own weight.
  • the dynamic contact angle is then measured at 10 seconds and at 70 seconds. The results are provided below:
  • the initial measurement of the dynamic contact angle at 10 seconds, provides a strong indication of the hydrophilicity of the release layer surface.
  • the subsequent measurement at 70 seconds provides an indication of the extent to which any liquid (such as a polyether glycol functionalized polydimethyl siloxane) disposed within the release layer has been incorporated into the drop. Such incorporation may further reduce the measured DCA.
  • the samples cured against PET exhibit substantially lower (more hydrophilic) initial DCA measurements (105°, 87°) relative to the hydrophilic initial DCA measurements (114°, 113°) of the respective samples cured against air.
  • the samples cured against PET exhibited a drop in DCA of 8 to 17° between the first and second measurements.
  • FIGS. 10A-10C provide images of various ink patterns printed onto a release layer of an ITM of the present invention, in which the release layer of Example 2 was cured against the PET carrier surface.
  • FIGS. 11A-11C are images of the same ink patterns printed onto a release layer of Example 2, but in which the release layer was cured against air. Comparing between FIGS. 10A and 11A , it is manifest that the release layer of the inventive ITM exhibits a higher optical density, and more accurately reflects the ink image pattern. A comparison between FIGS. 10C and 11C yields the identical conclusion. Comparing now between FIGS. 10B and 11B , it is evident that each ink dot in FIG. 10B is appreciably larger than the respective ink dots in FIG. 11B .
  • the term “receding contact angle” or “RCA”, refers to a receding contact angle as measured using a Dataphysics OCA15 Pro Contact Angle measuring device, or a comparable Video-Based Optical Contact Angle Measuring System, using the above-described Drop Shape Method, at ambient temperatures.
  • the analogous “advancing contact angle”, or “ACA”, refers to an advancing contact angle measured substantially in the same fashion.
  • dynamic contact angle refers to a dynamic contact angle as measured using a Dataphysics OCA15 Pro Contact Angle measuring device, or a comparable Video-Based Optical Contact Angle Measuring System, using the method elaborated by Dr. Roger P. Woodward in the above-referenced “Contact Angle Measurements Using the Drop Shape Method”, at ambient temperatures, and as elaborated hereinabove in Example 17.
  • standard aging procedure refers to an accelerated aging protocol performed on each tested release layer at 160° C., for 2 hours, in a standard convection oven.
  • standard air curing refers to a conventional curing process for curing the release layer, described with respect to Comparative Examples 1A-1F, in which, during the curing of the release layer, the release layer surface (or “ink reception surface”) is exposed to air.
  • bulk hydrophobicity is characterized by a receding contact angle of a droplet of distilled water disposed on an inner surface of the release layer, the inner surface formed by exposing an area of the cured silicone material within the release layer.
  • hydrophilicity and “hydrophilicity” and the like, may be used in a relative sense, and not necessarily in an absolute sense.
  • the term “functional group” refers to a group or moiety attached to the polymer structure of the release layer, and having a higher polarity than the O—Si—O group of conventional addition-cured silicones.
  • Various examples are provided herein. The inventors observe that pure addition cure polydimethyl siloxane polymer contains O—Si—O, SiO 4 , Si—CH 3 and C—C groups, and that most other functional groups will have a higher dipole, such that they may be considered “functional”. It will be appreciated by those of skill in the art that such functional groups, may have a tendency or strong tendency to react with components typically present in aqueous inks utilized in indirect inkjet printing, at process temperatures of up to 120° C.
  • % refers to percent by weight, unless specifically indicated otherwise.
  • ratio refers to a weight ratio, unless specifically indicated otherwise.

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  • Textile Engineering (AREA)
  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
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  • Laminated Bodies (AREA)
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